Method of winding dynamo-electric-machine elements



Nov. 4, 1930. v G APPLE 1,780,456

METHOD OF WINDING DYNAMO ELECTRIC MACHINE ELEMENTS Filed Nov. 9, 1928 2 Sheets-Sheet l F1 Z- 20 5 /7 2/ I IN VE N TOR.

V. G. APPLE Nov. 4, 1930.

METHOD OF WINDING DYNAMO ELECTRIC MACHINE ELEMENTS Filed Nov. 9, 1928 2 Sheets-Sheet 2 Patented Nov. 4, 1930 PATENT OFFICE VINCENT G. APPLE, OF DAYTON, OHIO METHOD OF WINDING DYNAMO-ELECTR-IC-MACHINE ELEMENTS Application filed November 9, 1928.

This invention relates to two layer bar wound armatures having integral commutator and winding units, and an object of the invention is to provide a form of winding loop which may be endwise entered into closed or semi-closed winding apertures, and a procedure whereby they may be bent and re-arranged in pairs to compose a winding having a commutator as an integral part thereof, 19 withoutsoldered, brazed or welded joints in any part of the circuit.

Another object is to so proportion the parts of the armature that lengths of conventional commutator bar stock may be used for the winding units.

I attain these and other objects by the procedure described and the structure shown in the drawings wherein- Fig. 1 shows how a length of commutator bar stock may be cut apart to form two conductor bars of different length and form.

Fig. 2 shows how the bars Fig. 1 are spread apart to loop form.

Fig. 3 shows several loops Fig. 2 assembled in a core.

Fig. 4 shows how the ends of the outer layer of conductors are bent radially outward to permit circumferential displacement of the ends of the inner layer.

Fig. 5 shows the ends of the inner layers of conductors circuinferentially displaced.

Fig. 6 shows the ends of the outer layer of conductors returned radially inward to their normal position.

Fig. 7 shows a completed armature.

Fig. 8 is a transverse section taken at 8-8 Fig. 7.

Fig. 9 is an elevation of a single pair of conductor ends bent as in Fig. 4.

Similar numerals refer to similar parts throughout the several views.

In carrying out my invention I employ for the conductor bars of the winding, bar stock of wedge shaped cross section, such as is commonly used to compose segments of a dynamo electric machine commutator.

Fig. 1 shows a length of such bar stock which has been cut apart at 10 forming from the piece a straight conductor bar 11 having a beveled end 12, and a relatively longer and Serial No. 318,223.

differently shaped conductor bar 13, having an upwardly projecting lug let beveled at 15 and 16, the two conductors being left joined together at the end 17.

The cut 10 should start relatively close to the end 17 and extend lengthwise of the bar to a point somewhat farther from the end 14, thence crosswise of the bar through one edge as at 12. T he cut 10 should not extend closer to the end than the width of a bar 11 or 13 and should stop somewhat farther from the end 1% since these ends 1 1 are ultimately to compose commutator segments.

After lengths of bar stock are cut apart as in F 1, the conductor bars are spread apart as in Fig. 2, the shorter bar 11 being adapted to occupy a position in the outer layer of the winding and the longer bar 13 being adapted to occupy a spaced apart position in the inner layer or" the winding. The back leads 18 and 19 are of substantially equal length so that the length of bar 11 from the bend 20 to the beveled end 12 is equal to the length of the bar 13 from the bend 21 to the notch 22.

After a number of loops equal to the nunr ber of winding apertures in the core are provided they are stacked in cylindrical formation, the bar 11 of each loop radially over the bar 13 of a difierent loop, and the beveled end 12 of each loop nesting in the notch 22 of a different loop, the composite cross sectional shape of each pair of re-arranged bars thus being the same as the pair 11 and 13 in Fig. 1, so that an entire winding, s0 stacked may pass endwise thru the core apertures. 0

Fig. 3 shows a core 23 having a plurality of winding apertures 24: with a sufficient number of loops entered to show how bars 11 may be paired with bars 13 with the beveled end 12 of one loop in the notch 22 of another, the manner in which the several loops are arranged being typical of the entire winding.

After the loops are assembled in the core as shown in Fig. 3, it is necessary that the ends of one layer of bars be circumferentially displaced relative to the ends of the other layer. so that the end of a bar of one layer may join a widely spaced apart bar of the other layer.

Since a bar 13 is longer than a bar 11 by so much as the length of the lug 14, and since the beveled ends 15 are intended ultimately to be even with the beveled ends 12, it follows that the bends or leads are preferably composed entirely of the inner bar. But since bending the inner bars shortens their axial length, it is apparent that there would be interference between the ends 12 and the lugs 14 while bending was being effected.

Toobviate this interference the ends of the bars 11 are first bent radially outward as in Fig. 4, a single bar so bent being shown in elevation in Fig.9, then the ends 14 are circumferentially'displaced as in Fig. 5 after which the bars v11 are replaced by bending separated one from another.

Fig. 7 shows the completed armature and ntegral'commutator wherein segments are composed, each of a bar 11 and a lug 14 in electrical contact, and where thin walls of insulation 26 extend between the segments, the larger mass 25 of insulation extending within and about the segments to bind them together. The transverse section Fig. 8 shows how pairs are held together to compose segments and the segments spaced apart to compose a commutator.

H-aving described my invention, I claim-4 1. The method of winding a dynamo elec tric machine element, which consists of providing lengths of bar stock, dividing each length from a point near one end to a point relatively farther from the other end thence outwardly thru one edge to compose of each length one. relatively short bar and another somewhat longer bar having an upwardly projecting lug at its free end, spreading apart the divided portions of each length to compose loops, assembling plurality of the loops in the apertures of a core, displacing the ends of the shorter bars outwardly from the core axis, circumferentially displacing the upwardly extending lugs of the longer bars, replacing the ends of the shorter bars to positions circnmferentially adjacent the upwardly extending lugs to form pairs, and binding the two parts of each pair together to complete the circuit.

2. The method of making a bar wound armature, which consists of providing lengths of wedge shaped bar stock, dividing each bars, replacing'the ends of theshorter bars to positions circumferentially adjacent the upwardly extending lugs to form pairs, and binding the two parts of each pair together to compose segments and the segments together to compose a commutator.

3. The method of making a bar wound armature, which consists of providing lengths of wedge shaped bar stock, dividing each length from a point near one end to a point relatively farther from the other end, thence outwardly thru one edge to compose of each length one relatively short bar and a somewhat longer bar having an upwardly proj ecting lug at its free end, spreading. apart the divided portions of each length to compose loops, assembling a plurality of the loops in the apertures of a core,,displacing the ends of the shorter bars outwardly from the core axis, circumferentially. V displacing the upwardly extending lugs of the longer bars, replacing the ends of the shorter bars to positions circumferent-ially adjacent the upwardly extending lugs to form pairs, and molding a mass of insulating material thru and about the ends of the bars in such a manner as will bind the two members of each pair together in intimate electrical contact to complete the circuit'and to form electrically spaced apart commutator segments, and the segments together to compose a commutator as an integral part of the winding.

4. Steps in the method of winding a dy namo electric machine element, which consist of providing lengths of bar stock, dividing each length from a point near one end to a point relatively farther from the other end,

thence outwardly thru one edge to compose of each length one relatively short bar and a somewhat longer bar having an upwardly projecting lug at its free end, spreading apart the divided portions of each length to compose loops, assembling a number of loops equal to the number ofcore apertures in cylindrical formation with the ends of the shorter bars resting in the spaces behind'the lugs from whence other short bars were previously cut, then simultaneously endwis e entering the entire winding into the core apertures. r

In testimony whereof I hereunto set my hand. I

VINCENT G. APPLE. 

